Process for producing tools used in orthopedic surgeries

Abstract

An orthopedic tool being made from an alloy in the group comprising stainless steel alloys, cobalt-chrome alloys, titanium alloys and alumina and zirconia ceramic alloys, and having a density less than 98% of a theoretical possible density for the alloy, the orthopedic tool being made by a metal injection moulding process.

1 . A surgical cutting guide being made from an alloy in the group comprising stainless steel alloys, cobalt-chrome alloys, titanium alloys and alumina and zirconia ceramic alloys, and having a density less than 98% of a theoretical possible density for the alloy, said surgical cutting guide being made by a metal injection moulding process. 
     
     
         2 . A process for making a surgical cutting guide, said process comprising:
 a. preparing a fluid feedstock including metallic powder selected from the group comprising stainless steel alloys, cobalt-chrome alloys, titanium alloys and alumina and zirconia ceramic alloys and binder material;   b. injecting the feedstock into a mold having cavity approximating the shape of the surgical cutting guide, to form a green part;   c. debinding the green part to provide a debound part;   d. sintering the debound part to yield said surgical cutting guide, wherein said preparing, injecting, debinding and sintering being performed at process conditions such that said surgical cutting guide has a density less than 98% of a theoretical possible density for the alloy.   
     
     
         3 . A process for making a surgical cutting guide, said process comprising:
 a. preparing a fluid feedstock including metallic powder selected from the group comprising stainless steel alloys, cobalt-chrome alloys, titanium alloys and alumina and zirconia ceramic alloys and binder material;   b. injecting the feedstock into a mold having cavity approximating the shape of the surgical cutting guide, to form a green part;   c. debinding the green part to provide a debound part;   d. sintering the debound part to yield a precursor of said surgical cutting guide, wherein said preparing, injecting, debinding and sintering being performed at process conditions such that said precursor has a density less than 98% of a theoretical possible density for the alloy;   e. performing one or more process step on said precursor to yield said surgical cutting guide, wherein said one or more process steps are such that said surgical cutting guide acquires a higher density than said precursor.